ashish shubh
TRANSCRIPT
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23RD SEPTEMBER 2010- 24TH OCTOBER 2010
KEC INTERNATIONAL LTD.(RPG CABLES)
SILVASSA
Induction Training Program
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Overview
y Company profile
y Line of action
y Basic cable construction
y Planning department
y Design department
y Production department
y Testing departmenty Engineering services
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KEC International ltd.
y
Kamani Engg. Corp. established for manufacture,enamelling and trading for Hollowware in 1945.
y Taken over by RPG group in 1982.
y Name changed to KEC International Ltd. in 1984.
y KEC International Ltd. took over RPG cables in 2010.y KEC today has excellent Project Management capabilities
in five major business areas:
y Power Transmission
y Power Distribution & Design Services
y Telecommunications Infrastructure
y Railway Infrastructure
y Cables Manufacturing
yWater harvesting
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RPG Cables Profile
Started in 1959 at Thane, Mumbai
Pioneer in Cable industry, headquartered in Mumbai, India.
Outcome of the merger of Asian Cables Ltd.(Thane), RPG Telecom
Ltd. (Mysore) & Upcom Cables Ltd (Rae Bareli) in 1995.
Oldest company of the RPG Group.
Part of the Transmission Sector of the RPG Group since 2008.
Brand name 'Asian' is 50 years old.
Approx 40000 shareholders.
KEC International Ltd. took over RPG cables in 2010.
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Product Range
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Products at silvassa
Power cables(1-4 cores,
10-1000mm2)
Control cables(1-61 cores,
1-10 mm2)
Special design cables(instrument
cable)
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Silvassa Plant
y Departments:
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Line Of Action
Customer
MARKETING
COSTING
PLANNING
ACCOUNTS
PURCHASE
PRODUCTION
Q/C TESTING
DESPATCH
CUSTOMER
DESIGN
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Cont..4 Filler To provide circular shape
to cable.
Non- hygroscopic.
Compatibility with insulation& sheathing material.
5 Inner sheath To bind cores of cable
together & provide a
bedding for armor.
Good mechanical & thermal
properties.
6 armor To provide protectionagainst external mechanical
forces.
To carry current during
fault conditions.
High mechanical strength,reasonable electrical
conductivity & corrosion
resistant.
7 Outer sheath To provide external
covering & protection to
the cable.
Good mechanical & thermal
properties. Flexibility.
Fire retardant, and low smoke,
anti-termite, uv resistance
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GUIDED BY:
MR.PRADEEP
Planning Department
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Department Interface
PLANNING
DESIGN
MARKETING
QUALITY
PRODUCTION
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Functions
y Interface between plant and marketing
y Freezing of order after technical and commercial
clearance
y
Decide delivery datey prepare production schedule for a month
y Provide raw material details to the purchase department
y keeps track of every job on the tracker
y Accordingly arrange the customer inspection date
y Dispatch
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Cable Type
SR.
NO.
CONSTITUENT CODE LETTER
1 Aluminum conductor A
2 XLPE insulation 2X
3 Steel round wire armor W 4 Non magnetic round wire armor Wa
5 Steel strip armor F
6 Non magnetic strip armor Fa
7 Double steel round wire armor WW
8 Double steel strip armor FF
9 PVC outer sheath Y
10 Extruded inner sheath (P)
11 Taped inner sheath (T)
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Cable Code
y 2550-18-03-80-00
2550
Type ofcable
(A2XFY(P))
18
Voltagegrade
1.1 kv
03
Number ofcores
3 core
80
Conductorcrosssectionalarea
300 mm sq.
00
Standard ornonstandard
standard
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Order confirmation number
y P 3070444
P
Party
Private
Govt.
State govt.
Export
1st digit
Region
1- baroda
2- mumbai
3- kolakata
Etc..
2nd digit
year
0- 2010
3rd digit
Insulation
2- PVC
7- XLPE
Last 4 digit
Serialcode
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GROUPS AS PER CONDUCTOR AREA:
y Group 1: 1.5 mm2 to 6 mm2
y Group 2: 10 mm2 to 50 mm2
y Group3: 70 mm2 to 150 mm2
y Group4: 185 mm2
to 1000 mm2
y Group h: house wiring
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Tracker
y Tracker is one of best example of MICROSOFT EXCEL
as a very effective tool in manufacturing industry.
y Tracker keeps up to date records of every raw material to
finished product.
y We manufacture 600+orders of cable in a month.
y We manufacture 400+ types of cables.
y So, it is a very tedious task to keep track of each and every
order.
y Everyone can keep a track of every work order with the help
of tracker.
y We can predict our plan of action if we are running late.
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GUIDED BY:
MR. S. KADAM
Design Department
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Department Interface
Design
Marketing
Planning
Production
QA &testing
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Functions
Shaping the requirements of the customer by applying
standards and engineering experience.
Receiving enquiries of floated tender from customers
through marketing department. Marketing department receives queries from regional
offices.
Prepares GTP, BOM & Offer as per requirement and
forwarded to marketing department.
Confirms the Quality assurance plan.
Prepares manufacturing specification and hand over to
production department.
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Standards
XLPE insulated PVC sheathed cables forworking voltages up to & including 1100 volt
IS 7098 (Part I)
For PVC Insulated cablesIS-1554 (Part-I)
Conductors for insulated electric cables &cords.
IS 8130
PVC insulation and sheath of electric cables.IS 5831
armoring of cables.IS -3975
There are some standards which are generally followed by the design
department on the basis of voltage grade of cable or customers
requirement.
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Design of cables:
y Conductor:
y The choice of conductor material, size and design must
take following into consideration.
yAmpacity
yVoltage stress at the conductor
y Voltage regulation
y Conductor losses
y Bending radius and flexibility
y Overall economics
y Material considerations
y Mechanical properties
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Material consideration
Metal Ohm-mm2/m x 10-8
Silver 1.629
Copper annealed 1.724
Copper hard drawn 1.777
Copper tinned 1.741 1.814
Aluminum, soft, 61.2% cond. 2.803
Aluminum, hard to full hard 2.828
Sodium 4.3
Nickel 7.8
Resistivity of metal at 20 0C
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y Large size of solid conductors becomes to rigid to form,
install and terminate.y In large size of solid conductor AC resistance is increased
due to skin effect and proximity.
y Stranding becomes solution to these problems.
y Types of stranding :y Concentric stranding
y Compressed stranding
y Compact stranding
y Bunch stranding
y Rope stranding
y Sector conductor
y Segmental conductor
y Annular conductor
y
Unilay conductor
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y Insulation
y Properties required
y Low dielectric constant
y Low power factor
y High dielectric strength
y Moisture resistance
y
High resistance to chemical and solventsy Materials
Polymer type Properties
LDPE Low dielectric loss
Moisture sensitiveXLPE Slightly higher losses vs. PE
Age better then PE
PVC Must contain plasticizer for
flexibility
Higher losses
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Comparison
Properties XLPE PE PVC
Normal Rated temp 90 70 70
Short ckt. Temp` 250 140 160
Tensile strength 2.35 1.4 1.25 to 2.5
Power factor x 10-4 4 4 1000
Volume resistivity at
20 0C
>10^15 >10^15 >10^13
Dielectric strength
KV/mm
50 50 20 to 35
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y Armoring
y Properties requiredy Reasonable conductivity
y Mechanical strength
y Flexible
y Materials
y G.S. flat wire
y G.S. round wire
yAluminumy Copper
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INSULATION TYPE TYPE OF OUTER
SHEATH
TYPE-A(700C) ST-1(700C)
TYPE- C(850C) ST-2(90
0C)
XLPE(900C) ST-2(90
0C)
OUTER SHEATHProperties required
Good mechanical & thermal properties.
Flexibility
Fire retardant
low smoke
anti-termite uv resistance
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Design calculation
y O.C. NO : P3070444
y TYPE : AX
y CABLE CODE : 2550 18 93 52 49
y CORES & CONDUCTOR AREA: 3.5C X 70MM2
y CUSTOMER NAME: ORISSA MANGANESE
y PRODUCTION PLAN: 4500 MTR
y CABLE CONSTRUCTION: A2XFY(P)
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WIRE DRAWING PROCESS
y
NUMBER OF WIRES ARE DECIDED BASED ON MIN WIREREQUIREMENT AS PER IS-8130/1984.
y Main conductor
y Wire diameter : 2.16 mm
y No. of wires : 19
y Weight Of Conductor = Area X Density X Compaction factor
= 19 X 0.7850 X 2.162 X 2.703 X 0.93
= 175 KG/KM
y FOR 4.5 KMS = 175 X 4.5
= 787.5 KG
y FOR 3 CORES = 787.5 X 3
= 2362.5 KG
y Neutral conductor
y Wire diameter : 2.52 mm
y No. of wires : 7
y Weight of neutral conductor = 394.94 KG
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STRANDING PROCESS
y Main conductor :
y Length required: 4.5 x 3c = 13.5 km
y Sector angle = 1000
y Depth of conductor =
= 8.95 mm
y Width of conductor =
= 13.71mm
y Neutral conductor
y Length required: 4.5 x 1c = 4.5 km
y Sector angle = 600
y Depth = 8.174 mm
y Width = 8.174 mm
deg
360
v
varea
depthvv2
sin2U
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INSULATION PROCESSy XLPE insulation :
y Nominal thickness: 1.1 mm (IS : 7098/I)
y Main Core diameter:
y Area = 0.7850 X d2
D1 = 9.28 mm
y Core diameter after XLPE insulation (dc1) = 9.28 + 2 x1.1
dc1 = 11.48mm
y Total weight of main conductor = area X density X length X no. of cores
= 445.5kg
y Neutral core diameter (d2)= 6.67 mm
y Core diameter over XLPE insulation (dc2)= 6.47 mm
y Weight of XLPE for neutral conductor = 88.61 kg
y Total weight of XLPE = 445.5 + 88.61
=534.11 kg
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y Laid up diameter (DT) = 2.48 x (3 x dc1 + dc2) / 4
= 25.96 mm
INNER SHEATH PROCESS
Thickness of I/SH = 0.4 mm (AS PER IS 7098/PART I)
Diameter over inner sheath (D3) = 25.97+2 x 0.4= 26.76 mm
Area of inner sheath = 0.7850 x (d32 - dt
2)
= 33.13 mm2
Weight of inner sheath = area x density of PVC (st-2) length
= 33.13 x 1.51 x 4.5
= 223.6 kg
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ARMORING PROCESS
y G.S. flat strip of 1.4 mm
y Diameter after armoring (d4) = diameter over I/SH + 2 x thickness
= 26.76 + (2 x 0.8)
= 28.37mm
y No. Of flat wires required = 3.142 x Dia.Under armoring x 90/armor size
=19
y Weight of armoring = area of wire x density of G.S.Wire x no. of wires x length
= (4 x 0.8) x 7.850 x 19 x 4.5
= 2147.76 kg
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OUTER SHEATH
y Minimum thickness of the outer sheath = 1.56 mm
y Diameter over outer sheath (d5) = d4 + 2x thickness
=31.48 mm
y Area of outer sheath = 146.63 mm2
y Total weight of outer sheath = area of outer sheath x density x length
= 996.38 kg
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GUIDED BY:MR. UMESH CHANDRA
MR. L.K.MISHRA
MR. YADAV
Production Department
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Department Interface
PRODUCTION
PLANNING
DESIGN
TESTING
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Functions
y Prepares master production schedule for a month
y Raw material requisition
y Prepare job cards from manufacturing specificationy Prepare job process sheet
y Update daily production shift wise in tracker
y Coordination with maintenance department
y Coordination of man, machine, material.
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Basic Process Flowchart
Wire
drawingAnnealing Redrawing Stranding
Insulation
Laying Up
1 core
Multicore
Inner
Sheath
armoringOuter
Sheath
Final
TestingDispatch
Raw
Materials
inspection
curing XLPE
PVC
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Machine layout
Plant 1
Sr. Name
1 11-die Al
2 9-die Cu
3 9-die Al
4 17-die fine Cu
5 7-die fine Al
6 19 bobbin
7 Winding m/c
8 Winding m/c
9 Winding m/c
10 42 bobbin new
11 37 bobbin
12 6+1 laying up
Sr. Name
13 Winding m/c
14 Winding m/c
15 32 bobbin
16 Annealing furnace
17 Cable rewinding
18 Cable rewinding
19 120 mm extruder
20 61 bobbin
21 Drum twister
22 Winding m/c
23 21 die Al
24 Office
25 workshop
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Machine layout
Sr. Name Sr. name
1 Buncher-1 13 150 mm extruder
2 Buncher-2 14 80 mm extruder
3 Buncher-3 15 64 bobbin
4 Winding m\c 16 Cable maintenance
5 45 mm extruder 17 42 bobbin old6 45 mm extruder 18 4+1 laying up
7 90 mm extruder 19 3+1 laying up
8 24 bobbin 20 Testing
9 Winding m/c 21 Testing
10 6+1 laying up 22 Winding m/c
11 Winding m/c 23 Winding m/c
12 60 mm extruder 24 Winding m/c
25 office
Plant 2
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Wire Drawing
y In wire drawing, the copper or aluminum rod is drawn
through a series of successively smaller dies to reduce the
rod to a wire of the desired diameter.
y Here the entire process is carried out in weight and not in
meters.
y Lubrication:
-For Copper wire- Soap foam /Draw Met 44
-For Aluminum wire- Draw Met 15
y Drawn wire is further send for Annealing in electric furnace.
Here the temperature is about 450 0 C , and due to which
wire becomes soft & then re-drawn
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Line diagram of 9 die RBD
RAW
MAT
E-
RIAL
WIRE
DRAWING
CHAMBER
DA
N-
CER-
2
DA
N-
CER-
1
ANNEALING
CHAMBER
TAKE-
UP
MAIN
MOTOR
MAIN MOTOR SPECIFICATION: 3-PHASE INDUCTION MOTOR
415 V, DELTA CONNECTED
160 KW, 1488 RPM
PF = 0.86
IP - 55
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Machine capacity
y Rated capacity :y Motor RPM = 1488 RPM
y Driver pulley = 9
y Driven pulley = 17.24
y Capstan RPM = motor RPM x pulley ratio x gear ratio
= 1488 x 9/17.24 x 45/57 x37/63
= 360 RPM
y Capstan circumference = 1.72 meter
y Line speed = 619.2 MPM
y Density of copper = 8890 kg/m^3
y Required diameter = 1.8 mm
y Weight = area x density x length
= 0.785 x 0.0018^2 x 8890 x 619.2
= 13.92 kg/min
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Sr. Gear RPM MPM KG/min
1 51/51 456 784.32 17.734
2 45/57 360 619.2 13.92
3 36/66 249 428.2 9.628
Rated capacity
Gear setting is dependent on wire size.
Machine capacity/hr = kg/min x 60
= 9.628 x 60= 577.68 kg / hr
Actual production =418 kg/hr
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Stranding machine
y The stranding of wire is done to make wire more flexible
reduce skin effect and proximity effect.
y Cold weld is used to weld two bobbins carrying aluminum
wires and electric welding is used for welding of copper
wires.
SR. NO MACHINE NAME AREA(MM2)
1 6+1(TUBLAR) 4-50
2 19 BOBIN 50-150
3 37 BOBIN 70-300
4 61 BOBIN 95-630
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MAIN MOTOR SPECIFICATION:
3-PHASE INDUCTION MOTOR
415 V, DELTA CONNECTED
75 KW
1475 RPM
93% EFFICIENCY
IP - 55
61 BOBBIN STRANDING
MACHINE
7
bobbin
12
bobbin
24
bobbin
18
bobbincapsta
ntake-up
GB GB GB GBMOTOR
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MACHINE CAPACITY
y Gearbox is used to reduce the rpm of each cage
y Lay depends on cage rpm and line speed
y Line speed is controlled by capstan gear box
y Line speed = (cage rpm x lay of conductor)/1000
y FOR 61-BOBBIN STRANDING MACHINE
y MOTOR RPM = 1475
y CAGE RPM AT LEVER LOW = 82
y LAY OF CONDUCTOR = 220 MM
y LINE SPEED = (82 X 220)/1000
=18.04 MPM
y MACHINE HOUR RATE = 18.04 X 60 = 1082.4 m/hr = 1.0824 km/hr
y IN 8 HRS SHIFT : 1.51 X 8 = 8.659 KMS/SHIFT
y ACTUAL PRODUCTION = 3.09 KMS/SHIFT
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19 BOBIN STRANDING MACHINE
1
BOBBI
N
6 BOBIN
CAGE
DIE
HOL
DER
12 BOBIN
CAGE
DIE &ROLLER
HOLDE
R
CAPSTONTAKE
- UP
Main motor specification:
3-phase induction motor
squirrel cage motor
415 v, delta connected
30 KW, 1470 rpm
54.5 A
IP - 55
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MACHINE CAPACITY
y LINE SPEED = (CAGE RPM X LAY OF CONDUCTOR)/1000
y FOR 19- BOBBIN STRANDING MACHINE
y MOTOR RPM = 1470
y CAGE RPM AT LEVER HIGH = 176
y LAY OF CONDUCTOR = 140 MM
y LINE SPEED = (176 X 140)/1000
=24.72 MPM
y MACHINE HOUR RATE = 24.72 X 60 = 1483 m/hr = 1.483 km/hr
y IN 8 HRS SHIFT : 1.483 X 8 = 11.86 KMS/SHIFT
y ACTUAL PRODUCTION = 4.544 KMS/SHIFT
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INSULATION
y Extrusion process is carried out to put the insulation layer on
conductor
y Compound, in the form of pellets is fed into the back of a screw
y screw rotates in a barrel. The material advances down the screw
and is melted during the advance.y The barrel is divided into zones which are individually
temperature controlled.
y depending on compound and extrusion parameters, barrel
cooling and even screw cooling may be required.
y Properly executed, the compound is all melted and forced
through a die-head arrangement that deposits the melt on the core
being passed through the head. This core may be a bare wire or
conductor.
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Extruder
MACHINE AREA
45mm extruder -I 1TO 4
45mm extruder-II 1 TO 6
60mm extruder 2.5 TO 70
120mm extruder 35 TO 630
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Extruder specification
SPEED
(rpm)
L/DRATIO
No. OFHEATING
ZONES
HEATINGCAPACITY
(kw)
TEMP.REG.
RANGE
(oC)
DRIVE(kw)
45mm
Extruder
10-120 24:1 4 2.4 100-250 15
60mm
Extruder
10-100 24:1 4 2.4 100-250 30
80mm
Extruder
10-100 24:1 4 100-250 45
90mm
Extruder
10-85 24:1 5 100-250 63
120mm
Extruder
8-80 24:1 5 100-250 150
150mm
Extruder
8-72 24:1 6 70 100-275 250
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Standard operating Procedure
y Empty the hopper completely and clean it
y Start the machine and drain the material which is in
screw
y Stop the machine
y Dismantle the screw and clean it
y Clean head, die, breaker plate and barrel
y Mount the screw
y Fit head, breaker plate, neck, tip, die on basis of job
y Preheat the screw temp for XLPE
Z1 Z2 Z3 Z4 Z5 NECK HEAD DIE
170 175 180 180 185 180 185 189
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y Preheat the catalyst at 60 0C for 4 hours
y Mix catalyst with XLPE (5%)y Mix color with mixture (0.03%-0.5%)
y Load mixture in hopper Load the job
y Start the extruder and do the centering until 95% is
achieved
y Pull the job from head and die
y Connect the job with lead wire
y Connect lead wire to caterpillar and close it
y Start and Set the speed according to thickness
y Cut joint and connect to drum Start the take up
y For PVC start the vacuum pump when cable is pulled in
head
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y Check the thickness and vary the caterpillar speed
accordingly
y For outer sheath only,
y Details of printing is fed into printer initially
yWhen cable reaches the printer start it
yAt the time of cutting the cable into different sizes based
on job reset the counter meter at panel and printer
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Curing
y Curing process is done only in the XLPE material
y The heating period to effect cross-linking is commonly
called curing
y It involves cross linking of c-c bond of sioplas(pe)
compound with the help of sillane compound
y Curing is the process in which insulated core is kept in
curing tank(85-90c)for standard time as per insulation
thickness
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y Curing time depends on the following factors:
y Thickness of insulationy Tank temperature
y Above given curing time is valid only if the tank temp. isabove 900C
Sr. Conductor area Curing time
1 300 6 to 8 hrs
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Laying up
y Laying up is the process to construct a skeleton of 3-
core cables
y Lay of Laid up core is always in right hand direction
y We have following laying up machine
SR.NO. MACINE AREA CORE
1 4+1 6-50 2 TO 5
2 3+1 70-630 2 TO 4
3 Drum twister 16-185 2 TO 4
4 24 Bobin 1.5-2.5 2 TO 61
5 6+1( Tubular) 1-4 2TO 7
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24 BOBBIN MACHINE
P
TRACKER
TAPING
HEADDIE
HOLDER6 BOBIN
CAGE
18 BOBIN
CAGEPAY-OFFDIE
HOLDER
CAPSTONTAKE-UP
37KW/50HP,
1440RPM,70AMP.,415V
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MACHINE CAPACITY
y Gearbox is used to reduce the rpm of each cage
y Lay depends on cage rpm and line speed
y Line speed is controlled by capstan gear box
y Line speed = (cage rpm x lay of conductor)/1000
y FOR 24 bobbin laying up machine
y MOTOR RPM = 1450
y CAGE RPM = 60 RPM
y LAY OF CONDUCTOR = 232 MM
y LINE SPEED = (60 X 232)/1000
=13.92 MPM
y MACHINE HOUR RATE = 13.92 X 60 = 835.2 m/hr = 0.8352km/hr
y IN 8 HRS SHIFT : 0.8352 X 8 = 6.68 KMS/SHIFT
y ACTUAL PRODUCTION = 3.52 KMS/SHIFT
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6+1 TUBULAR
1
bobbin
Gear boxTake
up
45KW SLIP-RING
MOTOR, 415V,1500RPM
Main
motor
Capstan
Gear-
box6 bobbin cage Die holder
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DRUM TWISTER
RDH TPHCATERP
ILLAR
BINDE
R
TAKE-
UP
4 PAY-OFF SECTORCORRECTION
ROTATING PART
SR
.
NAME KW VOLT RPM
1 Motor pay off 11 415 1455
2 Caterpillar belt 15 415 1435
3 Main motor 30 415 1465
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Inner sheath
y The inner sheath is required to protect the laid up core
and insulation from armoring.
y Compounds used PVC ST 1, PVC ST 2 and PE
y
Machines used for inner sheath are
y The inner sheath can be either extruded or tapped
MACHINE AREA
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 above
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Machines used for armoring
SERIAL
NO.
MACHINE TYPE AREA
1 42 BOBIN OLD GS ROUND
WIRE/FLATWIRE
1.5-16
2 42 BOBIN NEW GS ROUND
WIRE/FLATWIRE
1.5-16
3 32 BOBIN FLATWIRE 10-150
4 64 BOBIN GS ROUND
WIRE/FLATWIRE
185-1000
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64 BOBBIN ARMORING
Pay-off
24
bobbin
cage
42
bobbin
cage
Die holder
Capstan
Taping
head
Take-up Main motor(Slip-ring):
75kw, 136amp,
1400rpm,
415V
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Outer sheath
y The outer sheath is required to protect the armoring and
prevent the entry of moisture
y Compounds used PVC ST 2, FRLS(H), LSZH and PE in
special cases
y The large percentage of chlorine can be released during a
fire. When combined with moisture, hydrochloric acid maybe produced. This situation highlights one of the major
problems that can result from the use of PVC.
y So FRLS is used in the outer sheath
MACHINE AREA
90mm extruder 1 TO 70
80mm extruder 1 TO 50
150mm extruder 16 AND ABOVE
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Guided By:
Mrs. B. PANDYA
Mr. A. SINGH
Quality & Testing Department
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Department Interface
QUALITY
PRODUCTION
DESIGN
DESPATCH
PLANNING
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Functions
y Regulation of the quality of raw materials, packing
materials (wooden drum), In process checks and Final
testing of finished cables.
y Handling customer Inspections & preparation of
inspection reports and documents.
y Hold all non-conforming products prior to dispatch.
y Maintains BIS License.
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Standards
For 1.1 kv LT power & control cables, we have
following BIS License:
y IS-1554/Part-1/1988 (For PVC Insulated cables)
y IS-7098/Part-1/1988 (For XLPE Insulated cables)
y IS-694/1990 (For House Wiring cables)
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Quality Assurance Plan
y Quality is assured at every stage of cable manufacturing.
ProductQuality
Incoming RawMaterialsTesting
In-processQualityChecks
FinishedGoods
Testing
Routine
Test
Type
Test
Acceptance
Test
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I T i
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Inprocess Testing
WIREDRAWING
DIAMETER OFWIRE
TENSILE STRENGTH &WRAPPING TEST FOR Al
ANNEALING TEST FOR Cu
STRANDING
SEQUENCE
LAY LENGTH AND DIRECTION
SURFACE FINISH
EXTRUSION
THICKNESS OF INSULATION
DIA OF INSULATION
SPARK TEST
PURPOSE:
To inspect & Test in process products as per QAP , hold all non conformingproducts & release in process products for further production .
Cost saving.
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Routine Test
These type of tests made by the manufacturers on all finish cable
lengths to demonstrate the integrity of cable.
y Conductor Resistance Test :- This describes the energylosses due to current flow through the cable and therefore has an
important role in determining cable temperature.
y High Voltage Test (at room temperature):- Theinsulation material in a cable is used to isolate the conductors
from one another and from ground as well as provide the
necessary mech. Strength. It is necessary that an evaluation of the
condition of the insulation be met by imposing a higher voltage
stress for a short duration.
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Tests carried out on samples taken from a lot for the purposeacceptance of the lot.
Conductor Resistance Test,
Annealing Test (For Copper),
Tensile Strength Test (For Aluminum),
Wrapping Test (For Aluminum),
Tests for Thickness of Insulation and Sheath,
Hot Set Tests For Insulation,
Tensile Strength and elongation at break test for Insulation & O.S High Voltage Test at room temperature
Insulation Resistance (Volume Resistivity) Test
Acceptance Test
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Special Tests to be carried out, when required, by agreement
between the Purchaser & Supplier.
Cold Impact Tests for outer sheath (IS:5831/1984) and
part 21 of IS:10810) shall constitute the optional Test.
Cold bend Tests for outer sheath (IS:5831/1984) and part
20 of IS:10810) shall constitute the optional Test.
Optional Test
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GUIDED BY:
Mr. P.N. SINGH
Mr. A. PATIL
Engineering Services
Department
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Functions of Department
y Periodic Maintenance of every machine on theshop floor.
yAttending Breakdowns
y Making job orders, indents & preserving maintenance records.
y Maintenance of Electrical Sub Station, Utilities.
y Development Activities to improve the Plant
Productivity.
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Preventive Maintenance
yYearly preventive maintenance schedule is prepared forall machines.
yAs per yearly schedule, monthly preventive schedule ismade.
yAs per the schedule & availability of machine,Department attends to the machines & undertakesactivities listed in PM checklist.
y Necessary machine modifications are done inconsultation with respective HODs.
y Records of inspections carried out by external agenciesare maintained in Engineering Department.
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Breakdown Maintenance
In case of any machine breakdown, the concerned dept.informs the Engineering Dept.
The Dept. analyzes the nature of breakdown & takes
necessary action.
The required spare parts are taken from the stores.
Incase the spare parts are not available, the Dept. prepares
the Indent & forward it to the materials Dept.
At the same time if possible the Dept. provide thetemporary arrangement to start the machine.
Necessary entries regarding the breakdown are made in
Log book.
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Utilities
y HOT WATER
GENERATOR
OUT PUT : 400000
KCAL/HR
MAX. TEMP. :1400C
FUEL :HSD
y WATER CHILLING PLANT
COMPRESSOR
CAPACITY 32 KW
TOTAL CAPACITY 40 TR
COMPRESSOR IR1(100 Psi)
IR2(125 Psi)
IR3(125Psi)
ELGI(250 Psi)
DG SETS 750 KVA
320 KVA
FORK LIFT &HYDRA
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Constructional Features
y It is a fully automatic, forced circulation, coil type, water tube,three pass, oil fired type Hot Water Generator.
y It consists of two concentric helical coils which are concentricwith inner and outer jacket.
y The inner coil forms the combustion chamber; the annularspace between the two coils is used as a second pass for flue gaswhile space between outer coil and inner jacket is used as thirdpass for flue gases.
y The space between the two jackets is used for passing the airrequired for the combustion.
y Water is pumped and passed through outer coil & then it entersthe inner coil at the rear end and then comes out. During this ,water is heated by flue gases.
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Fuel Modulation
y Fuel modulation takes place as per the hot water temp.which is sensed by temp. transmitter.
y Depending on the HW temp. the transmitter gives
proportional current o/p which is given as i/p to a PID
controller which in turn controls the blower.
y The blower receives signal to increase or decrease fuel
o/p by perfectly matching positions of fuel metering
valve & air damper till desired hot water generator is
stabilized.
y Whole operating sequence is controlled by the
sequence controller to which a flame sensor is also
connected.
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Operating Control Procedure
y Ensure water tank is fully leveled before start.
y Ensure that there is no leakage of HSD/Waste oil.
y Set the temperature of water to which is required to be
maintained.
y Check all the safety valves and NRVs.
y Ensure all the switches are in operating position.
y Ensure hot water pipelines are fully insulated.
y Ensure the hot water operation is auto-cut whentemperature is maintained.
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Diesel Generator
y 12 Cylinder - Kirloskar Cummins DG
y Capacity : 750 KVA , Rpm: 1500 (max)
440 v , 50 Hz , 1000 A
y Cooling: Water cooled through Cooling Tower
Forced Draft
y Heat Exchanger: Shell & Tube Type
y Lubrication: oil ( oil sump-165 liters)
y Consumption: Diesel (3 units/litre)
y Self excited AVR used
y Miscellaneous: Vibration Damper, Turbocharger
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Work Instruction
Ensure
water circulation pump
proper battery connection
optimum engine oil level
diesel line valve in open condition
switch in idle position
proper coolant water level proper water level in cooling tank
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DG Set Troubleshooting
Air system
Air cleaner
(leakage)
Improper airtemperature
Dirtyturbochargercompressor
Fuel system
Air leaks in
suction lines
Injector flowincorrect
Broken fuelpump drive
shaft
Lubricatingsystem
Dirty oil filter
Crankcase lowor out of oil
Wrong gradeoil for weather
conditions
Coolingsystem
Insufficient
coolant
Faultythermostat
Coolanttemperature
low
Mechanicalrepair
Flywheel
balance
Worn pistons& piston rings
Broken toothof gears
Misalignedbearings
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1- 90 mm , 400 A 27- CAPACITOR, 250 A
2- 42 ARM ,200 A 28- DT ,250 A
3- LIGHTING .200 A 29- FURNACE, 32 B, 250 A
4- 6+1 ,200 A 30- 120 mm, 400A
5- DG ROOM ,400 A 31- HEAVY REW 3 , 250 A
6- 80 mm, 200 A 32- 61 B, 400 A
7- STRIP REW, 200A 33- 42 B NEW, 250 A
8- LIGHTING, 200 A 34- 6+1 TUB, 250 A
9- 72 B ARM, 200A
10- 24 B,200 A
11- 3+1, 200 A
12- TEST HOUSE, HWG, 200A
13- 4+1, 200 A
14- 37 B, 200 A
15- 19 B,WATER PUMP, 200 A
16- CAPACITOR, 200 A
17- 11 DIE RBD, 800 A
18- 150 mm, 600A
19- 9 DIE Al, 400 A
20- 9 DIE CU, 630 A
21- CAPACITOR,250 A
22- 150 mm MIXTURE, 250 A
23- EOT CRANE 15T, 250 A
24- 17 DIE CU, 250 A
25 CHILLING 250 A